JP2021154317A - Method of manufacturing liquid-cooled jacket - Google Patents

Abstract

To provide a method of manufacturing a liquid-cooled jacket that can appropriately join metal made of different materials to each other and grasp a passing position of a rotary tool.SOLUTION: The method of manufacturing a liquid-cooled jacket includes: a main joining step in which a tip end face of a protrusion part F4 is inserted at a depth equal to or slightly larger than the depth of a bottom surface 12a of a step, while contacting a flat surface F3 of a stirring pin F2 of a rotary tool F that rotates with only a sealed body 3, and a crude dense part with a predetermined width is formed at a site close to a side surface 12b of the step in a plasticized region W1, while friction-stirring a first butted part J1 by making the rotary tool F rotate once around the first butted part, with only the stirring pin F2 slightly contacted with at least an upper side of the jacket main body 2; and an inspecting step in which flaw detection for detecting the crude dense part is performed after the main joining step so as to identify a passing position of the stirring pin F2.SELECTED DRAWING: Figure 6

Description

The present invention relates to a method for manufacturing a liquid-cooled jacket.

A method for manufacturing a liquid-cooled jacket using friction stir welding is used. For example, Patent Document 1 discloses a method for manufacturing a liquid-cooled jacket. FIG. 13 is a cross-sectional view showing a conventional method for manufacturing a liquid-cooled jacket. In the conventional method for manufacturing a liquid-cooled jacket, the butt portion J10 formed by abutting the step side surface 101c provided on the step portion of the aluminum alloy jacket body 101 and the side surface 102c of the aluminum alloy sealing body 102. This is to perform friction stir welding. Further, in the conventional method for manufacturing a liquid-cooled jacket, only the stirring pin FD2 of the rotary tool FD is inserted into the butt portion J10 to perform friction stir welding. Further, in the conventional method for manufacturing a liquid-cooled jacket, the rotation center axis XA of the rotation tool FD is overlapped with the butt portion J10 and relatively moved.

Japanese Unexamined Patent Publication No. 2015-131321

Here, the jacket body 101 tends to have a complicated shape. For example, a jacket body 101 formed of a cast material of 4000 series aluminum alloy and a relatively simple shape such as a sealing body 102 is a wrought material of 1000 series aluminum alloy. In some cases, it is formed by. In this way, a liquid-cooled jacket may be manufactured by joining members of different grades of aluminum alloy. In such a case, the jacket body 101 generally has a higher hardness than the sealing body 102. Therefore, when friction stir welding is performed as shown in FIG. 13, the stirring pin FD2 becomes the sealing body 102. The material resistance received from the jacket body 101 side is larger than the material resistance received from the side. Therefore, it becomes difficult to stir different grades in a well-balanced manner by the stirring pin of the rotary tool FD, and there is a problem that cavity defects occur in the plasticized region after joining and the joining strength decreases.

Further, after the liquid-cooled jacket is completed, the quality of the liquid-cooled jacket may be controlled by, for example, performing an ultrasonic flaw detection inspection. At this time, although it is possible to grasp the presence or absence of joint defects by ultrasonic flaw detection inspection, there is a problem that it is not possible to grasp which position the rotation tool has passed. Further, it is desired to further improve the bonding strength of the liquid-cooled jacket.

Further, when the stirring pin FD2 is separated from the butt portion J10, the stirring pin FD2 is moved in the vertical direction, so that the frictional heat at the start position of frictional stirring becomes excessive. As a result, at the start position, the metal on the jacket body 101 side is likely to be mixed into the sealing body 102 side, which causes a problem of contributing to poor joining.

Further, when the stirring pin FD2 is separated from the butt portion J10, the stirring pin FD2 is moved in the vertical direction, so that the frictional heat at the end position of frictional stirring becomes excessive. As a result, at the end position, the metal on the jacket body 101 side is likely to be mixed into the sealing body 102 side, which causes a problem of contributing to poor joining.

From this point of view, it is an object of the present invention to provide a method for manufacturing a liquid-cooled jacket, which can suitably join aluminum alloys of different grades and can grasp the passing position of a rotating tool. do.

In order to solve such a problem, the present invention comprises rotating a jacket body having a bottom portion and a peripheral wall portion rising from the peripheral edge of the bottom portion, and a sealing body for sealing the opening of the jacket body, provided with a stirring pin. A method for manufacturing a liquid-cooled jacket to be joined using a tool. The jacket body is a grade having a hardness higher than that of the sealing body, and the outer peripheral surface of the stirring pin is inclined so as to be tapered. The stirring pin has a flat surface perpendicular to the rotation center axis at its tip, and also has a protrusion protruding from the flat surface. A preparatory step of forming a peripheral wall stepped portion having a stepped side surface rising toward the opening, and a stepped side surface of the peripheral wall stepped portion and an outer peripheral side surface of the sealing body by placing the sealing body on the jacket body. The first butt portion is formed by abutting the two, and the bottom surface of the step and the back surface of the sealing body are overlapped to form the second butt portion. While bringing the flat surface into contact with only the sealing body, the tip surface of the protrusion is inserted at the same depth as or slightly deeper than the bottom surface of the step, and the outer peripheral surface of the stirring pin is inserted into the jacket body. The step in the plasticized region while the rotating tool is circulated around the rotating tool along a set movement route set on the sealing body side of the first abutting portion in a state of being slightly in contact with at least the upper side. The main joining step of forming a coarse and dense portion having a predetermined width in a portion close to the side surface is included, and in the main joining step, the rotating stirring pin is inserted at a start position set further inside than the set movement route. After that, the stirring pin is gradually pushed in until it reaches a predetermined depth while moving the rotation center axis of the rotation tool to a position overlapping the set movement route.

According to such a manufacturing method, the metal of the first butt portion mainly on the sealing body side is agitated and plastically fluidized by the frictional heat between the sealing body and the stirring pin, and the step side surface and the outer circumference of the sealing body are formed at the first butt portion. Can be joined to the side surface. Further, since only the stirring pin is slightly brought into contact with at least the upper side of the stepped side surface of the jacket body to perform friction stir welding, it is possible to minimize the mixing of metal from the jacket body to the sealing body while ensuring the joint strength. .. As a result, in the first butt portion, the metal on the sealing body side is mainly frictionally agitated, so that a decrease in joint strength can be suppressed. Further, by gradually pushing the stirring pin until it reaches a predetermined depth while moving the rotation tool to a position overlapping the set movement route, it is possible to prevent the frictional heat from becoming excessive on the set movement route.

Further, by intentionally forming a coarse and dense portion having a predetermined width, the passing position of the stirring pin can be grasped by the flaw detection inspection. As a result, the quality control work can be performed more easily. Further, by forming the outer peripheral surface of the stirring pin and the side surface of the step so as to be inclined, it is possible to avoid large contact between the stirring pin and the side surface of the step. Further, since the plastic fluid material wound around the protrusion is pressed by the flat surface, the oxide film of the second butt portion can be reliably separated. Thereby, the joint strength of the second butt portion can be increased.

Further, in the present invention, a liquid for joining a jacket body having a bottom portion and a peripheral wall portion rising from the peripheral edge of the bottom portion and a sealing body for sealing the opening of the jacket body using a rotating tool provided with a stirring pin. In a method for manufacturing a cold jacket, the jacket body is a grade having a hardness higher than that of the sealing body, and the outer peripheral surface of the stirring pin is inclined so as to be tapered. A flat surface perpendicular to the rotation center axis is provided at the tip thereof, and a protrusion protruding from the flat surface is provided, and a step bottom surface and a step rising from the step bottom surface toward the opening are provided on the inner peripheral edge of the peripheral wall portion. The preparatory step of forming the peripheral wall stepped portion having the side surface, and the first abutment by placing the sealing body on the jacket body and abutting the stepped side surface of the peripheral wall stepped portion with the outer peripheral side surface of the sealing body. A mounting step of forming a portion and superimposing the bottom surface of the step and the back surface of the sealing body to form a second butt portion, and sealing the flat surface of the stirring pin of the rotating tool. While contacting only the body, the tip surface of the protrusion is inserted at the same depth as or slightly deeper than the bottom surface of the step, and the outer peripheral surface of the stirring pin is slightly contacted with at least the upper side of the jacket body. In this state, the rotating tool is circulated around the set movement route set on the sealing body side of the first butt portion and frictionally agitated, and the portion close to the step side surface in the plasticized region is designated. Including the main joining step of forming a coarse and dense portion of the width, the stirring pin is inserted from the start position set on the set movement route in the main joining step, and the stirring pin is moved in the traveling direction to reach a predetermined depth. It is characterized in that the stirring pin is gradually pushed in until.

According to such a manufacturing method, the metal of the first butt portion mainly on the sealing body side is agitated and plastically fluidized by the frictional heat between the sealing body and the stirring pin, and the step side surface and the outer circumference of the sealing body are formed at the first butt portion. Can be joined to the side surface. Further, since only the stirring pin is slightly brought into contact with at least the upper side of the stepped side surface of the jacket body to perform friction stir welding, it is possible to minimize the mixing of metal from the jacket body to the sealing body while ensuring the joint strength. .. As a result, in the first butt portion, the metal on the sealing body side is mainly frictionally agitated, so that a decrease in joint strength can be suppressed. Further, by gradually pushing the stirring pin until it reaches a predetermined depth while moving the rotation tool on the set movement route, it is possible to prevent the frictional heat from becoming excessive at one point on the set movement route.

Further, by intentionally forming a coarse and dense portion having a predetermined width, the passing position of the stirring pin can be grasped by the flaw detection inspection. As a result, the quality control work can be performed more easily. Further, by forming the outer peripheral surface of the stirring pin and the side surface of the step so as to be inclined, it is possible to avoid large contact between the stirring pin and the side surface of the step. Further, since the plastic fluid material wound around the protrusion is pressed by the flat surface, the oxide film of the second butt portion can be reliably separated. Thereby, the joint strength of the second butt portion can be increased.

Further, in the present joining step, the rotation tool is rotated at a predetermined rotation speed to perform frictional stirring, and when the stirring pin is inserted in the main joining step, the rotation speed is higher than the predetermined rotation speed. It is preferable to insert the stirring pin in a state of being rotated at a speed and move the stirring pin to the set movement route while gradually reducing the rotation speed.

According to such a joining method, friction stir welding can be performed more preferably.

Further, in the present invention, a liquid for joining a jacket body having a bottom portion and a peripheral wall portion rising from the peripheral edge of the bottom portion and a sealing body for sealing the opening of the jacket body using a rotating tool provided with a stirring pin. In a method for manufacturing a cold jacket, the jacket body is a grade having a hardness higher than that of the sealing body, and the outer peripheral surface of the stirring pin is inclined so as to be tapered. A flat surface perpendicular to the rotation center axis is provided at the tip thereof, and a protrusion protruding from the flat surface is provided, and a step bottom surface and a step rising from the step bottom surface toward the opening are provided on the inner peripheral edge of the peripheral wall portion. The preparatory step of forming the peripheral wall stepped portion having the side surface, and the first abutment by placing the sealing body on the jacket body and abutting the stepped side surface of the peripheral wall stepped portion with the outer peripheral side surface of the sealing body. A mounting step of forming a portion and superimposing the bottom surface of the step and the back surface of the sealing body to form a second butt portion, and sealing the flat surface of the stirring pin of the rotating tool. While contacting only the body, the tip surface of the protrusion is inserted at the same depth as or slightly deeper than the bottom surface of the step, and the outer peripheral surface of the stirring pin is slightly contacted with at least the upper side of the jacket body. In this state, the rotating tool is circulated around the set movement route set on the sealing body side of the first butt portion and frictionally agitated, and the portion close to the step side surface in the plasticized region is designated. Including the main joining step of forming a coarse and dense portion of the width, in the main joining step, the end position is set further inside than the set movement route, and after frictional stirring joining with respect to the first butt portion, the rotation The stirring pin is gradually pulled out from the sealing body while moving the tool to the ending position, and the rotating tool is separated from the sealing body at the ending position.

According to such a manufacturing method, the metal of the first butt portion mainly on the sealing body side is agitated and plastically fluidized by the frictional heat between the sealing body and the stirring pin, and the step side surface and the outer circumference of the sealing body are formed at the first butt portion. Can be joined to the side surface. Further, since only the stirring pin is slightly brought into contact with at least the upper side of the stepped side surface of the jacket body to perform friction stir welding, it is possible to minimize the mixing of metal from the jacket body to the sealing body while ensuring the joint strength. .. As a result, in the first butt portion, the metal on the sealing body side is mainly frictionally agitated, so that a decrease in joint strength can be suppressed. Further, by gradually pulling out the stirring pin while moving the rotation tool to the end position set inside the set movement route, it is possible to prevent the frictional heat from becoming excessive on the set movement route.

Further, by intentionally forming a coarse and dense portion having a predetermined width, the passing position of the stirring pin can be grasped by the flaw detection inspection. As a result, the quality control work can be performed more easily. Further, by forming the outer peripheral surface of the stirring pin and the side surface of the step so as to be inclined, it is possible to avoid large contact between the stirring pin and the side surface of the step. Further, since the plastic fluid material wound around the protrusion is pressed by the flat surface, the oxide film of the second butt portion can be reliably separated. Thereby, the joint strength of the second butt portion can be increased.

Further, the manufacture of a liquid-cooled jacket in which a jacket body having a bottom portion and a peripheral wall portion rising from the peripheral edge of the bottom portion and a sealing body for sealing the opening of the jacket body are joined by using a rotating tool provided with a stirring pin. In the method, the jacket body is a grade having a higher hardness than the sealing body, the outer peripheral surface of the stirring pin is inclined so as to be tapered, and the stirring pin rotates to the tip thereof. It has a flat surface perpendicular to the central axis, has a protrusion protruding from the flat surface, and has a step bottom surface and a step side surface rising from the step bottom surface toward the opening on the inner peripheral edge of the peripheral wall portion. In the preparatory step of forming the peripheral wall step portion to be held, the sealing body is placed on the jacket body, and the step side surface of the peripheral wall step portion and the outer peripheral side surface of the sealing body are abutted to form the first abutting portion. At the same time, the mounting step of forming the second butt portion by superimposing the bottom surface of the step and the back surface of the sealing body, and the flat surface of the stirring pin of the rotating tool contacting only the sealing body. The tip surface of the protrusion is inserted at the same depth as the bottom surface of the step or slightly deeper than the bottom surface of the step, and the outer peripheral surface of the stirring pin is slightly in contact with at least the upper side of the jacket body. While rubbing and stirring the rotating tool around the set movement route set on the sealing body side of the first butt portion, a coarse and dense portion having a predetermined width is located in the plasticized region close to the step side surface. In the main joining step, the end position is set on the set movement route, and after the friction stirring joint with respect to the first butt portion, the rotation tool is moved to the end position. It is characterized in that the stirring pin is gradually pulled out from the sealing body while allowing the stirring pin to be separated from the sealing body at the end position.

According to such a manufacturing method, the metal of the first butt portion mainly on the sealing body side is agitated and plastically fluidized by the frictional heat between the sealing body and the stirring pin, and the step side surface and the outer circumference of the sealing body are formed at the first butt portion. Can be joined to the side surface. Further, since only the stirring pin is slightly brought into contact with at least the upper side of the stepped side surface of the jacket body to perform friction stir welding, it is possible to minimize the mixing of metal from the jacket body to the sealing body while ensuring the joint strength. .. As a result, in the first butt portion, the metal on the sealing body side is mainly frictionally agitated, so that a decrease in joint strength can be suppressed. Further, by gradually pulling out the stirring pin toward the end position while moving the rotation tool on the set movement route, it is possible to prevent the frictional heat from becoming excessive at one point on the set movement route.

Further, by intentionally forming a coarse and dense portion having a predetermined width, the passing position of the stirring pin can be grasped by the flaw detection inspection. As a result, the quality control work can be performed more easily. Further, by forming the outer peripheral surface of the stirring pin and the side surface of the step so as to be inclined, it is possible to avoid large contact between the stirring pin and the side surface of the step. Further, since the plastic fluid material wound around the protrusion is pressed by the flat surface, the oxide film of the second butt portion can be reliably separated. Thereby, the joint strength of the second butt portion can be increased.

In the main joining step, the rotation tool is rotated at a predetermined rotation speed to perform frictional stirring, and when the stirring pin is separated in the main joining step, the rotation speed is gradually increased from the predetermined rotation speed. It is preferable to move it to the end position.

According to such a joining method, friction stir welding can be performed more preferably.

According to the method for manufacturing a liquid-cooled jacket and the friction stir welding method according to the present invention, it is possible to grasp the passing position of the rotating tool while suitably joining metals of different grades.

It is a side view which shows the rotation tool which concerns on embodiment of this invention. It is a perspective view which shows the preparation process of the manufacturing method of the liquid-cooled jacket which concerns on 1st Embodiment of this invention. It is sectional drawing which shows the mounting process of the manufacturing method of the liquid-cooled jacket which concerns on 1st Embodiment. It is a perspective view which shows the main joining process of the manufacturing method of the liquid-cooled jacket which concerns on 1st Embodiment. It is sectional drawing which shows the main joining process of the manufacturing method of the liquid-cooled jacket which concerns on 1st Embodiment. It is a top view which shows the main joining process of the manufacturing method of the liquid-cooled jacket which concerns on 1st Embodiment. It is sectional drawing which shows after the main joining process of the manufacturing method of the liquid-cooled jacket which concerns on 1st Embodiment. It is a top view which shows the inspection process of the manufacturing method of the liquid-cooled jacket which concerns on 1st Embodiment. It is a figure which shows the example which separated the outer peripheral surface of a stirring pin from the step side surface. It is a figure which shows the example which made the outer peripheral surface of a stirring pin largely contact with the side surface of a step. It is a top view which shows this joining process of the manufacturing method of the liquid-cooled jacket which concerns on 2nd Embodiment of this invention. It is a top view which shows the main joining process of the manufacturing method of the liquid-cooled jacket which concerns on 2nd Embodiment. It is sectional drawing which shows the manufacturing method of the conventional liquid-cooled jacket.

Embodiments of the present invention will be described with reference to the drawings as appropriate. The present invention is not limited to the following embodiments. In addition, some or all of the components in each embodiment can be combined as appropriate. First, a rotary tool used in the method for manufacturing a liquid-cooled jacket according to the present embodiment will be described. The rotary tool is a tool used for friction stir welding. As shown in FIG. 1, the rotary tool F is formed of, for example, tool steel, the connecting portion F1 has a columnar shape, and a screw hole (not shown) to which a bolt is fastened is formed.

The stirring pin F2 hangs down from the connecting portion F1 and is coaxial with the connecting portion F1. Further, the stirring pin F2 includes a flat surface F3 and a protrusion F4. The stirring pin F2 is tapered as it is separated from the connecting portion F1. At the tip of the stirring pin F2, a flat flat surface F3 that is perpendicular to the rotation center axis X and is flat is formed. The protrusion F4 is a portion of the flat surface F3 that protrudes downward from the center. The shape of the protrusion F4 is not particularly limited, but is, for example, a columnar shape. A stepped portion is formed by the side surface of the protruding portion F4 and the flat surface F3.

That is, the outer surface of the stirring pin F2 is composed of a tapered outer peripheral surface, a flat surface F3 formed at the tip thereof, and a protruding portion F4 protruding downward from the central portion of the flat surface F3. When viewed from the side, the inclination angle α formed by the rotation center axis X and the outer peripheral surface of the stirring pin F2 may be appropriately set in the range of, for example, 5 ° to 40 °.

A spiral groove is engraved on the outer peripheral surface of the stirring pin F2. In the present embodiment, in order to rotate the rotation tool F clockwise, the spiral groove is formed counterclockwise from the base end to the tip end. In other words, the spiral groove is formed counterclockwise when viewed from above when the spiral groove is traced from the base end to the tip end.

When the rotation tool F is rotated counterclockwise, it is preferable to form the spiral groove clockwise from the base end to the tip end. In other words, the spiral groove in this case is formed clockwise when viewed from above when the spiral groove is traced from the base end to the tip end. By setting the spiral groove in this way, the metal plastically fluidized during friction stir welding is guided to the tip end side of the stirring pin F2 by the spiral groove. As a result, the amount of metal that overflows to the outside of the metal member to be joined (jacket body 2 and sealing body 3), which will be described later, can be reduced.

The rotation tool F is attached to the rotation shaft of the friction stirr. The rotation tool F may be attached to a robot arm provided with a rotation driving means such as a spindle unit at the tip thereof, for example. As a result, the rotation center axis X of the rotation tool F can be freely tilted.

[First Embodiment]
A method for manufacturing a liquid-cooled jacket according to an embodiment of the present invention will be described in detail with reference to the drawings. As shown in FIG. 2, the method for manufacturing the liquid-cooled jacket 1 according to the embodiment of the present invention is to manufacture the liquid-cooled jacket 1 by friction stir welding the jacket body 2 and the sealing body 3. The liquid-cooled jacket 1 is a member in which a heating element (not shown) is installed on the sealing body 3 and a fluid is allowed to flow inside to exchange heat with the heating element. In the following description, the "front surface" means the surface opposite to the "back surface".

The method for manufacturing a liquid-cooled jacket according to the present embodiment includes a preparation step, a mounting step, a main joining step, and an inspection step. The preparation step is a step of preparing the jacket body 2 and the sealing body 3. The jacket body 2 is mainly composed of a bottom portion 10 and a peripheral wall portion 11. The jacket body 2 is formed mainly containing a first aluminum alloy. As the first aluminum alloy, for example, an aluminum alloy casting material such as JISH5302 ADC12 (Al—Si—Cu system) is used. Although the jacket body 2 is exemplified by an aluminum alloy in this embodiment, it may be another metal capable of friction stir welding.

As shown in FIG. 2, the bottom portion 10 is a plate-shaped member having a rectangular shape in a plan view. The peripheral wall portion 11 is a wall portion that rises in a rectangular frame shape from the peripheral edge portion of the bottom portion 10. A peripheral wall step portion 12 is formed on the inner peripheral edge of the peripheral wall portion 11. The peripheral wall step portion 12 is composed of a step bottom surface 12a and a step side surface 12b rising from the step bottom surface 12a. The step side surface 12b is inclined so as to spread outward from the step bottom surface 12a toward the opening. The inclination angle β of the step side surface 12b with respect to the vertical plane may be appropriately set, and is, for example, 3 ° to 30 ° with respect to the vertical plane. A recess 13 is formed in the bottom portion 10 and the peripheral wall portion 11. Here, the vertical plane is defined as a plane composed of the traveling direction vector and the vertical direction vector of the rotation tool F.

The sealing body 3 is a plate-shaped member that seals the opening of the jacket body 2. The sealing body 3 has a size to be placed on the peripheral wall step portion 12. The plate thickness of the sealing body 3 is larger than the height dimension of the step side surface 12b. The plate thickness dimension of the sealing body 3 is appropriately set so that the joint portion does not run out of metal during the main joining step described later. The sealing body 3 is formed mainly containing a second aluminum alloy. The second aluminum alloy is a material having a lower hardness than the first aluminum alloy. The second aluminum alloy is formed of, for example, an aluminum alloy wrought material such as JIS A1050, A1100, A6063. Although the aluminum alloy is exemplified in this embodiment, the sealing body 3 may be another metal capable of friction stir welding. In the present specification, the hardness refers to Brinell hardness, which can be measured by a method according to JIS Z 2243.

As shown in FIG. 3, the mounting step is a step of mounting the sealing body 3 on the jacket body 2. In the mounting step, the back surface 3b of the sealing body 3 is mounted on the bottom surface 12a of the step. The step side surface 12b and the outer peripheral side surface 3c of the sealing body 3 are abutted to form the first abutting portion J1. The first butt portion J1 may include a case where the first butt portion J1 is butt-butted with a gap having a substantially V-shaped cross section as in the present embodiment. Further, the step bottom surface 12a and the back surface 3b of the sealing body 3 are overlapped to form the second butt portion J2.

As shown in FIG. 4, the “set movement route L1” (dashed line) is set inside the first butt portion J1. As will be described later, in the set movement route L1, in the present embodiment, the upper side of the outer peripheral surface of the stirring pin F2 is slightly in contact with the upper part of the step side surface 12b of the peripheral wall step portion 12, and the lower side of the outer peripheral surface is the peripheral wall step portion. The set movement route L1 is set to have a rectangular shape in a plan view inside the outer peripheral surface of the sealing body 3 in order to set the step surface 12b so as not to come into contact with the step side surface 12b.

In this joining step, friction stir is continuously performed in the closet section, the main section, and the detachment section. In the closet section of the main joining step, as shown in FIG. 4, friction stirring is performed from the start position SP1 set on the surface 3a of the sealing body 3 to the intermediate point S1 set on the set movement route L1. In the closet section, the rotation center axis X of the rotation tool F is arranged so as to be perpendicular to the start position SP1, and the stirring pin F2 is gradually pushed in until it reaches a predetermined depth while moving relative to the intermediate point S1. go.

At this time, as shown in FIG. 5, the stirring pin F2 is gradually pushed in so as to reach a predetermined depth set in advance by at least reaching the intermediate point S1. That is, instead of keeping the rotation tool F in one place, the rotation tool F is gradually lowered while being moved to the set movement route L1. When the rotation tool F reaches the intermediate point S1, the section shifts to this section as it is. A plasticized region W1 is formed in the movement locus of the rotation tool F.

The predetermined depth is the main section from the intermediate point S1 on the set movement route L1 to the intermediate point S2 set on the set movement route L1 after going around the set movement route L1 and passing through the intermediate point S1. Refers to the depth at which the stirring pin F2 is inserted. In the present embodiment, the flat surface F3 of the stirring pin F2 is brought into contact with only the sealing body 3, and the tip surface of the protrusion F4 is inserted so as to be slightly deeper than the step bottom surface 12a of the peripheral wall step portion 12. .. The flat surface F3 of the stirring pin F2 may be brought into contact with only the sealing body 3, and the tip surface of the protrusion F4 may be inserted so as to be at the same height as the step bottom surface 12a of the peripheral wall step portion 12. ..

In this section, as shown in FIG. 5, friction stir welding is performed in a state where the rotation center axis X of the rotation tool F is parallel to the vertical line (vertical face). With the stirring pin F2 maintained at a predetermined depth, the rotation tool F is moved so that the rotation center axis X and the set movement route L1 overlap. The inclination angle β (see FIG. 3) of the step side surface 12b is set to be smaller than the inclination angle α of the outer peripheral surface of the stirring pin F2. In this joining step, the upper side of the outer peripheral surface of the rotary tool F is slightly brought into contact with the upper portion of the step side surface 12b of the peripheral wall step portion 12, while the lower side of the outer peripheral surface is not brought into contact with the step side surface 12b of the peripheral wall step portion 12. Set.

As shown in FIG. 6, in this section, when the rotation tool F is made to go around the sealing body 3, the start end and the end of the plasticized region W1 on the set movement route L1 overlap, and the stirring pin F2 is an intermediate point. When it reaches S2, the process proceeds to the withdrawal process as it is.

In the detachment section, the stirring pin F2 is gradually moved upward from the intermediate point S2 toward the end position EP1, and the stirring pin F2 is detached from the sealing body 3 at the end position EP1. That is, the rotation tool F is gradually pulled out while being moved to the end position EP1 without staying in one place.

As shown in FIG. 7, when this joining step is performed, a plasticized region W1 is formed in the movement locus of the rotation tool F, and a coarse-dense portion Z is formed in the lower portion of the plasticized region W1 near the inside of the step side surface 12b. It is formed. The coarse-dense portion Z is a region where the stirring of the plastic fluid material is insufficient, and is a region where the plastic fluid material is coarser and denser than other portions. The coarse and dense portion Z is formed continuously or intermittently in the longitudinal direction of the plasticized region W1.

As shown in FIG. 8, the inspection step is a step of performing a flaw detection inspection of the liquid-cooled jacket 1. In the inspection process, an ultrasonic flaw detector (for example, an ultrasonic imaging device (SAT) manufactured by Hitachi High-Technologies Corporation) is used. In the inspection result screen R in FIG. 8, the hollow portion U of the liquid-cooled jacket 1 is displayed in color. Further, the coarse and dense portion Z is colored around the hollow portion U and is displayed in a frame shape and a linear shape. That is, by displaying the coarse and dense portion Z on the inspection result screen R, it can be specified that the rotation tool F has passed over the entire circumference of the sealing body 3. The portion between the hollow portion U and the coarse-dense portion Z is a portion corresponding to the plasticized region W1.

Here, the width Zw of the coarse-dense portion Z is preferably set to 400 μm or less, preferably 300 μm or less, and more preferably 200 μm or less. If the width Zw of the coarse and dense portion Z exceeds 400 μm, the joint strength of the first butt portion J1 may be insufficient. In other words, if the width Zw of the coarse and dense portion Z is 400 μm or less, sufficient bonding strength can be obtained. On the other hand, the width Zw of the coarse and dense portion Z is preferably 100 μm or more. If the width Zw of the coarse and dense portion Z is less than 100 μm, the ultrasonic flaw detector may not display the coarse and dense portion Z on the inspection result screen R.

As shown in FIG. 5, in the main joining step, the ratio of the region where the outer peripheral surface of the stirring pin F2 and the step side surface 12b contact and the region where the step side surface 12b does not contact is about 2: 8 in the present embodiment. , The jacket body 2 and the sealing body 3 may be appropriately set within a range in which the above-mentioned coarse and dense portion Z having a predetermined width is formed while being bonded to each other with a desired strength. In other words, the inclination angle α of the outer peripheral surface of the stirring pin F2, the inclination angle β of the step side surface 12b of the peripheral wall step portion 12, and the position (position in the width direction) of the rotation center axis X of the stirring pin F2 are sealed with the jacket body 2. It may be appropriately set within the range in which the coarse and dense portion Z having the predetermined width is formed while being joined to the stop body 3 with a desired strength.

As shown in FIG. 9, if the outer peripheral surface of the stirring pin F2 and the step side surface 12b are separated from each other, the joining may not be possible or the joining strength may decrease. It is preferable to bring them into contact. Further, as shown in FIG. 10, when the contact allowance between the stirring pin F2 and the step side surface 12b becomes large, a large amount of metal of the jacket body 2 having high hardness flows into the sealing body 3 side having low hardness, so that the jacket body 2 The balance between stirring and the sealing body 3 may become poor, and the bonding strength may decrease. Further, in the vicinity of the step bottom surface 12a, if the outer peripheral surface of the stirring pin F2 and the step side surface 12b are too close to each other or too far apart, it becomes difficult to form the coarse and dense portion Z having the above-mentioned predetermined width.

According to the method for manufacturing a liquid-cooled jacket according to the present embodiment described above, the metal mainly on the sealing body 3 side of the first butt portion J1 is agitated by the frictional heat between the sealing body 3 and the stirring pin F2, and the metal is plastic. It is fluidized, and the step side surface 12b and the outer peripheral side surface 3c of the sealing body 3 can be joined at the first butt portion J1. Further, since only the stirring pin F2 is slightly brought into contact with at least the upper side of the step side surface 12b of the jacket body 2 to perform friction stir welding, metal is mixed from the jacket body 2 into the sealing body 3 as much as possible while ensuring the bonding strength. Can be reduced. As a result, in the first butt portion J1, the metal on the sealing body 3 side is mainly frictionally agitated, so that a decrease in joint strength can be suppressed.

Further, since the tip surface of the protrusion F4 is inserted at the same level as or slightly deeper than the step bottom surface 12a, metal is mixed into the sealing body 3 from the jacket body 2 while increasing the joining strength at the second butt portion J2. Can be reduced as much as possible. Further, by intentionally forming the coarse and dense portion Z having a predetermined width, the passing position of the stirring pin F2 can be grasped by the flaw detection inspection. As a result, the quality control work can be performed more easily. Further, by forming the outer peripheral surface of the stirring pin F2 and the step side surface 12b so as to be inclined, it is possible to avoid large contact between the stirring pin F2 and the step side surface 12b, and the width Zw, size, etc. of the coarse and dense portion Z can be prevented. Can be easily controlled. Further, by increasing the thickness of the sealing body 3, it is possible to prevent a metal shortage at the joint portion.

Further, in the stirring pin F2, a protrusion F4 protruding from the flat surface F3 is formed. That is, a stepped portion is formed by the flat surface F3 of the stirring pin F2 and the protruding portion F4. Therefore, since the plastic fluid material wound around the protrusion F4 is pressed by the flat surface F3, the oxide film of the second butt portion J2 can be reliably divided. Thereby, the joint strength of the second butt portion J2 can be increased.

Further, in the closet section of the main joining process, the set movement route is gradually pushed in until the stirring pin F2 reaches a predetermined depth while moving the rotation tool F from the start position SP1 to a position overlapping the set movement route L1. It is possible to prevent the rotation tool F from stopping on L1 and causing the frictional heat to become excessive. Similarly, in the separation section of the main joining step, the stirring pin F2 is gradually pulled out from a predetermined depth while moving the rotation tool F from the set movement route L1 to the end position EP1 to separate the stirring pin F2 on the set movement route L1. It is possible to prevent the rotation tool F from stopping and excessive frictional heat.

As a result, it is possible to prevent the frictional heat from becoming excessive on the set movement route L1 and the secondary aluminum alloy from being excessively mixed from the sealing body 3 to the jacket main body 2 to cause poor bonding.

Further, in the main joining step, the positions of the start position SP1 and the end position EP1 may be appropriately set, but the angle formed by the start position SP1 and the set movement route L1 and the angle formed by the end position EP1 and the set movement route L1 are different. By setting the angle to be obtuse, it is possible to smoothly shift to the main section or the departure section without reducing the moving speed of the rotation tool F at the intermediate points S1 and S2. As a result, it is possible to prevent the frictional heat from becoming excessive due to the rotation tool F stopping or the moving speed decreasing on the set movement route L1. The rotation tool F may be moved from the start position SP1 to the set movement route L1 so that the locus of the rotation tool F draws a curve when viewed from above. Similarly, the rotation tool F may be moved from the set movement route L1 to the end position EP1 so that the locus of the rotation tool F draws a curve when viewed from above. The curve may be, for example, an arcuate locus.

Further, in the present joining step, the rotation direction and the traveling direction of the rotation tool F may be appropriately set, but in the present embodiment, the jacket body 2 side of the plasticized region W1 formed in the movement locus of the rotation tool F is sheared. The rotation direction and the traveling direction of the rotation tool F were set so as to be on the side and the sealing body 3 side was on the flow side. As a result, the stirring action by the stirring pin F2 around the first butt portion J1 is enhanced, and the temperature rise in the first butt portion J1 can be expected. Can be joined more reliably. Further, by forming the outer peripheral surface of the stirring pin F2 and the step side surface 12b so as to be inclined, it is possible to prevent the stirring pin F2 and the step side surface 12b from coming into large contact with each other.

The shear side (Advancing side) means the side where the relative speed of the outer circumference of the rotating tool with respect to the jointed portion is the value obtained by adding the magnitude of the moving speed to the magnitude of the tangential velocity on the outer circumference of the rotating tool. .. On the other hand, the flow side (Retreating side) refers to the side in which the relative speed of the rotating tool with respect to the jointed portion becomes low due to the rotation of the rotating tool in the direction opposite to the moving direction of the rotating tool.

Further, the first aluminum alloy of the jacket body 2 is a material having a higher hardness than the second aluminum alloy of the sealing body 3. Thereby, the durability of the liquid-cooled jacket 1 can be enhanced. Further, it is preferable that the first aluminum alloy of the jacket body 2 is an aluminum alloy casting material and the second aluminum alloy of the sealing body 3 is an aluminum alloy wrought material. By using an Al—Si—Cu based aluminum alloy casting material such as JIS H5302 ADC12 as the first aluminum alloy, the castability, strength, machinability, etc. of the jacket body 2 can be improved. Further, by using, for example, JIS A1000 series or A6000 series as the second aluminum alloy, processability and thermal conductivity can be improved.

For example, in the present embodiment, the plate thickness of the sealing body 3 is made larger than the height dimension of the step side surface 12b, but both may be the same. Further, the step side surface 12b may not be inclined and may be perpendicular to the step bottom surface 12a.

[Second Embodiment]
Next, a method for manufacturing a liquid-cooled jacket according to the second embodiment of the present invention will be described. As shown in FIGS. 11 and 12, in the second embodiment, the positions of the start position SP2 and the end position EP2 in the main joining step are different from those in the first embodiment. In the second embodiment, the parts different from the first embodiment will be mainly described.

In the method for manufacturing a liquid-cooled jacket according to the second embodiment, a preparation step, a mounting step, a main joining step, and an inspection step are performed. The preparation step, the placement step, and the inspection step are the same as those in the first embodiment.

As shown in FIG. 11, in the main joining step of the present embodiment, the start position SP2 is set on the set movement route L1 on the upstream side of the intermediate point S1. Further, the end position EP2 is set on the set movement route L1 on the downstream side of the intermediate point S2.

In this joining process, the intrusion section from the start position SP2 to the intermediate point S1, the main section from the intermediate point S1 on the set movement route L1 to the intermediate point S2, and the departure from the intermediate point S2 to the end position EP2. Friction stir welding is performed continuously for three sections.

In the closet section of the main joining step, as shown in FIG. 11, friction stir welding is performed from the start position SP2 to the intermediate point S1. In the closet section, the stirring pin F2 rotated clockwise is inserted into the start position SP2 and moved to the intermediate point S1. At this time, the stirring pin F2 is gradually pushed in so as to reach a predetermined depth set in advance by at least reaching the intermediate point S1.

When the intermediate point S1 is reached, the process proceeds to friction stir welding in this section as it is. As shown in FIG. 12, in this section, the rotation tool F is moved so that the rotation center axis (not shown) of the stirring pin F2 and the set movement route L1 overlap. The contact allowance between the stirring pin F2 and the step side surface 12b and the insertion depth of the stirring pin F2 are the same as those in the first embodiment.

When the stirring pin F2 reaches the intermediate point S2, the process shifts to the withdrawal section as it is. In the detachment section, the stirring pin F2 is gradually moved upward from the intermediate point S2 toward the ending position EP2, and the stirring pin F2 is moved from the sealing body 3 at the ending position EP2 set on the set movement route L1. To leave.

The method for manufacturing the liquid-cooled jacket according to the second embodiment described above can also achieve substantially the same effect as that of the first embodiment. Further, in the closet section of the main joining step according to the second embodiment, the set movement route L1 is gradually pushed in until the stirring pin F2 reaches a predetermined depth while moving the rotation tool F on the set movement route L1. It is possible to prevent the rotation tool F from stopping at the above point and causing the frictional heat to become excessive. Further, in the detachment section of the main joining step according to the second embodiment, the rotation tool F is moved on the set movement route L1 and the stirring pin F2 is gradually detached so that the rotation tool F can be rotated at one point on the set movement route L1. It is possible to prevent F from stopping and excessive frictional heat. The start position SP2 and the end position EP2 in the main joining step may be set on the set movement route L1 as in the second embodiment.

1 Liquid-cooled jacket 2 Jacket body 3 Encapsulant F Rotating tool F1 Connecting part F2 Stirring pin F3 Flat surface F4 Projection part J1 First butt part J2 Second butt part W1 Plasticized area Z Coarse and dense part

Claims (8)

A method for manufacturing a liquid-cooled jacket in which a jacket body having a bottom portion and a peripheral wall portion rising from the peripheral edge of the bottom portion and a sealing body for sealing an opening of the jacket body are joined by using a rotating tool equipped with a stirring pin. There,
The jacket body is a grade having a hardness higher than that of the sealed body.
The outer peripheral surface of the stirring pin is inclined so as to be tapered, and the stirring pin has a flat surface perpendicular to the rotation center axis at its tip and has a protrusion protruding from the flat surface.
A preparatory step of forming a peripheral wall step portion having a step bottom surface and a step side surface rising from the step bottom surface toward the opening on the inner peripheral edge of the peripheral wall portion.
The sealing body is placed on the jacket body, and the stepped side surface of the peripheral wall step portion and the outer peripheral side surface of the sealing body are abutted to form the first abutting portion, and the step bottom surface and the sealing body are formed. A mounting process in which the back surface is overlapped to form a second butt portion,
While the flat surface of the stirring pin of the rotating tool is brought into contact with only the sealing body, the tip surface of the protrusion is inserted at the same depth as or slightly deeper than the bottom surface of the step. With the outer peripheral surface of the stirring pin slightly in contact with at least the upper side of the jacket body, the rotary tool is rotated around the set movement route set on the sealing body side of the first abutting portion to stir friction. Including the main joining step of forming a coarse and dense portion having a predetermined width at a portion of the plasticized region close to the side surface of the step.
In the main joining step, after inserting the rotating stirring pin into the set start position further inside the set movement route, while moving the rotation center axis of the rotation tool to a position overlapping the set movement route. A method for manufacturing a liquid-cooled jacket, which comprises gradually pushing in the stirring pin until it reaches a predetermined depth. In the main joining step, the rotary tool is rotated at a predetermined rotation speed to perform friction stir welding.
When the stirring pin is inserted in the main joining step, the stirring pin is inserted in a state of being rotated at a speed higher than the predetermined rotation speed, and the stirring pin is moved to the set movement route while gradually reducing the rotation speed. The method for manufacturing a liquid-cooled jacket according to claim 1. A method for manufacturing a liquid-cooled jacket in which a jacket body having a bottom portion and a peripheral wall portion rising from the peripheral edge of the bottom portion and a sealing body for sealing an opening of the jacket body are joined by using a rotating tool equipped with a stirring pin. There,
The jacket body is a grade having a hardness higher than that of the sealed body.
The outer peripheral surface of the stirring pin is inclined so as to be tapered, and the stirring pin has a flat surface perpendicular to the rotation center axis at its tip and has a protrusion protruding from the flat surface.
A preparatory step of forming a peripheral wall step portion having a step bottom surface and a step side surface rising from the step bottom surface toward the opening on the inner peripheral edge of the peripheral wall portion.
The sealing body is placed on the jacket body, and the stepped side surface of the peripheral wall step portion and the outer peripheral side surface of the sealing body are abutted to form the first abutting portion, and the step bottom surface and the sealing body are formed. A mounting process in which the back surface is overlapped to form a second butt portion,
While the flat surface of the stirring pin of the rotating tool is brought into contact with only the sealing body, the tip surface of the protrusion is inserted at the same depth as or slightly deeper than the bottom surface of the step. With the outer peripheral surface of the stirring pin slightly in contact with at least the upper side of the jacket body, the rotary tool is rotated around the set movement route set on the sealing body side of the first abutting portion to stir friction. Including the main joining step of forming a coarse and dense portion having a predetermined width at a portion of the plasticized region close to the side surface of the step.
In the main joining step, the liquid is characterized in that the stirring pin is inserted from the start position set on the set movement route, and the stirring pin is gradually pushed in until the depth reaches a predetermined depth while moving in the traveling direction. How to make a cold jacket. In the main joining step, the rotary tool is rotated at a predetermined rotation speed to perform friction stir welding.
When the stirring pin is inserted in the main joining step, the stirring pin is inserted in a state of being rotated at a speed higher than the predetermined rotation speed, and the stirring pin is moved to the set movement route while gradually reducing the rotation speed. The method for manufacturing a liquid-cooled jacket according to claim 3, wherein the liquid-cooled jacket is manufactured. A method for manufacturing a liquid-cooled jacket in which a jacket body having a bottom portion and a peripheral wall portion rising from the peripheral edge of the bottom portion and a sealing body for sealing an opening of the jacket body are joined by using a rotating tool equipped with a stirring pin. There,
The jacket body is a grade having a hardness higher than that of the sealed body.
The outer peripheral surface of the stirring pin is inclined so as to be tapered, and the stirring pin has a flat surface perpendicular to the rotation center axis at its tip and has a protrusion protruding from the flat surface.
A preparatory step of forming a peripheral wall step portion having a step bottom surface and a step side surface rising from the step bottom surface toward the opening on the inner peripheral edge of the peripheral wall portion.
The sealing body is placed on the jacket body, and the stepped side surface of the peripheral wall step portion and the outer peripheral side surface of the sealing body are abutted to form the first abutting portion, and the step bottom surface and the sealing body are formed. A mounting process in which the back surface is overlapped to form a second butt portion,
While the flat surface of the stirring pin of the rotating tool is brought into contact with only the sealing body, the tip surface of the protrusion is inserted at the same depth as or slightly deeper than the bottom surface of the step. With the outer peripheral surface of the stirring pin slightly in contact with at least the upper side of the jacket body, the rotary tool is rotated around the set movement route set on the sealing body side of the first abutting portion to stir friction. Including the main joining step of forming a coarse and dense portion having a predetermined width at a portion of the plasticized region close to the side surface of the step.
In the main joining step, the end position is set further inside than the set movement route, and after friction stir welding with respect to the first butt portion, the stirring pin is sealed while moving the rotation tool to the end position. A method for manufacturing a liquid-cooled jacket, which comprises gradually pulling out from a stationary body to separate the rotating tool from the sealing body at the end position. In the main joining step, the rotary tool is rotated at a predetermined rotation speed to perform friction stir welding.
The method for manufacturing a liquid-cooled jacket according to claim 5, wherein when the stirring pin is detached in the main joining step, the stirring pin is moved to the end position while gradually increasing the rotation speed from the predetermined rotation speed. .. A method for manufacturing a liquid-cooled jacket in which a jacket body having a bottom portion and a peripheral wall portion rising from the peripheral edge of the bottom portion and a sealing body for sealing an opening of the jacket body are joined by using a rotating tool equipped with a stirring pin. There,
The jacket body is a grade having a hardness higher than that of the sealed body.
The outer peripheral surface of the stirring pin is inclined so as to be tapered, and the stirring pin has a flat surface perpendicular to the rotation center axis at its tip and has a protrusion protruding from the flat surface.
A preparatory step of forming a peripheral wall step portion having a step bottom surface and a step side surface rising from the step bottom surface toward the opening on the inner peripheral edge of the peripheral wall portion.
The sealing body is placed on the jacket body, and the stepped side surface of the peripheral wall step portion and the outer peripheral side surface of the sealing body are abutted to form the first abutting portion, and the step bottom surface and the sealing body are formed. A mounting process in which the back surface is overlapped to form a second butt portion,
While the flat surface of the stirring pin of the rotating tool is brought into contact with only the sealing body, the tip surface of the protrusion is inserted at the same depth as or slightly deeper than the bottom surface of the step. With the outer peripheral surface of the stirring pin slightly in contact with at least the upper side of the jacket body, the rotary tool is rotated around the set movement route set on the sealing body side of the first abutting portion to stir friction. Including the main joining step of forming a coarse and dense portion having a predetermined width at a portion of the plasticized region close to the side surface of the step.
In the main joining step, an end position is set on the set movement route, and after friction stir welding with respect to the first butt portion, the stirring pin is moved from the sealing body while moving the rotation tool to the end position. A method for manufacturing a liquid-cooled jacket, which comprises gradually pulling out the rotary tool from the sealing body at the end position. In the main joining step, the rotary tool is rotated at a predetermined rotation speed to perform friction stir welding.
The method for manufacturing a liquid-cooled jacket according to claim 7, wherein when the stirring pin is detached in the main joining step, the stirring pin is moved to the end position while gradually increasing the rotation speed from the predetermined rotation speed. ..

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